U.S. patent number 8,357,528 [Application Number 13/156,675] was granted by the patent office on 2013-01-22 for microfabricated compositions and processes for engineering tissues containing multiple cell types.
This patent grant is currently assigned to The Charles Stark Draper Laboratory, The General Hospital Corporation. The grantee listed for this patent is Jeffrey T. Borenstein, Joseph P. Vacanti, Eli Weinberg. Invention is credited to Jeffrey T. Borenstein, Joseph P. Vacanti, Eli Weinberg.
United States Patent |
8,357,528 |
Vacanti , et al. |
January 22, 2013 |
Microfabricated compositions and processes for engineering tissues
containing multiple cell types
Abstract
The present invention relates to a three-dimensional system, and
compositions obtained therefrom, wherein individual layers of the
system comprise channels divided longitudinally into two
compartments by a centrally positioned membrane, and wherein each
compartment can comprise a different cell type.
Inventors: |
Vacanti; Joseph P. (Winchester,
MA), Borenstein; Jeffrey T. (Newton, MA), Weinberg;
Eli (Cambridge, MA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Vacanti; Joseph P.
Borenstein; Jeffrey T.
Weinberg; Eli |
Winchester
Newton
Cambridge |
MA
MA
MA |
US
US
US |
|
|
Assignee: |
The General Hospital
Corporation (Boston, MA)
The Charles Stark Draper Laboratory (Cambridge, MA)
|
Family
ID: |
34434805 |
Appl.
No.: |
13/156,675 |
Filed: |
June 9, 2011 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20110256619 A1 |
Oct 20, 2011 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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10557081 |
Jun 14, 2011 |
7960166 |
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PCT/US2004/016059 |
May 21, 2004 |
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60472230 |
May 21, 2003 |
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Current U.S.
Class: |
435/284.1;
435/395; 435/299.1; 435/297.1 |
Current CPC
Class: |
C12N
5/0062 (20130101); C12N 5/0697 (20130101); C12N
5/0068 (20130101); C12N 2533/40 (20130101); B33Y
80/00 (20141201) |
Current International
Class: |
C12M
1/14 (20060101) |
References Cited
[Referenced By]
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10000823 |
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EP |
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JP |
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Aug 1994 |
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JP |
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WO-9609423 |
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Mar 1996 |
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WO |
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WO |
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WO |
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WO |
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WO |
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WO |
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Oct 2002 |
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Apr 2003 |
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WO |
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WO-03061585 |
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Jul 2003 |
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WO |
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WO-200401098 |
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Dec 2003 |
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WO |
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WO-2004020341 |
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Mar 2004 |
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WO |
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WO-2010009307 |
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Jan 2010 |
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WO |
|
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Primary Examiner: Ford; Allison
Attorney, Agent or Firm: Edwards Wildman Palmer LLP Lauro,
Esq.; Peter C. Chaclas, Esq.; George N.
Government Interests
STATEMENT OF GOVERNMENT INTEREST
The United States government has certain rights in this invention
by virtue of grant number DAMD-17-02-2-0006.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No.
10/557,081 now U.S. Pat. No. 7,960,166, which is the U.S. national
phase, pursuant to 35 U.S.C. .sctn.371, of PCT international
application Ser. No. PCT/US2004/016059, filed May 21, 2004,
designating the United States and published in English on Apr. 21,
2005 as publication WO/2005/034624, which claims priority from U.S.
Provisional Patent Application Ser. No. 60/472,230, filed on May
21, 2003. The entire contents of the aforementioned patent
applications are incorporated herein by this reference.
Reference is also made herein to International Application No.
PCT/US2004/001098, filed Jan. 16, 2004, that published in English
on Aug. 5, 2004 as publication WO/2004/065616. Reference is also
made herein to U.S. Ser. No. 10/187,247, filed Jun. 28, 2002, now
U.S. Pat. No. 7,759,113, which claims priority to U.S. Ser. No.
60/367,675, filed Mar. 25, 2002, and which is a CIP of Ser. No.
09/560,480, filed Apr. 28, 2000, now U.S. Pat. No. 6,455,311, which
claims priority to U.S. Ser. No. 60/165,329, filed Nov. 12, 1999
and to U.S. Ser. No. 60/131,930, filed Apr. 30, 1999, the contents
each of which are expressly incorporated herein by reference.
Reference is also made herein to U.S. Ser. No. 10/528,737, which is
the U.S. national phase of International Appln. No.
PCT/US2003/029880, filed Sep. 23, 2003, that published in English
on Apr. 1, 2004 as publication WO/2004/026115, which claims
priority to U.S. Ser. No. 60/412,981, filed on Sep. 23, 2002, and
U.S. Ser. No. 60/449,291, filed on Feb. 21, 2003, the contents of
each of which are expressly incorporated herein by reference.
Claims
What is claimed is:
1. A three-dimensional system comprising at least two layers,
wherein each layer comprises channels divided longitudinally into
two compartments by a centrally positioned membrane, and wherein
each compartment includes a different cell type and the membrane
has pores sized to enable only fluid communication.
2. The system of claim 1, further comprising a support element for
each layer.
3. The system of claim 1, wherein the membrane further comprises a
solid material contained within at least one pore of the
membrane.
4. The system of claim 1, further comprising a bridge connecting
two sections of the same compartment.
5. The system of claim 1, further comprising a bridge connecting a
compartment of one channel to a compartment of another channel.
6. The system of claim 5, wherein the bridge connects compartments
having same cell types.
7. The system of claim 5, wherein the bridge connects compartments
having primary cells in one of the connected compartments and
compatible cells in the other connected compartment for providing
support to the primary cells.
8. A three-dimensional system comprising: at least two layers,
wherein each layer comprises channels divided longitudinally into
two compartments by a centrally positioned membrane, and wherein
each compartment includes a different cell type and the membrane
defines pores for fluid communication between the two compartments;
and a bridge connecting a compartment of one channel to a
compartment of another channel, wherein the bridge connects
compartments having primary cells in one of the connected
compartments and compatible cells in the other connected
compartment for providing support to the primary cells.
Description
Each of the applications and patents cited in this text, as well as
documents or references cited in each of the applications and
patents (including during the prosecution of each issued patent;
"application cited document") and each of the PCT and foreign
applications and patents, and each of the documents cited or
referenced in each of the application cited documents, are hereby
expressly incorporated herein by reference, and may be employed in
the practice of the invention. More generally, documents or
references are cited in this text, either in a Reference List
before the claims, or in the text itself; and, each of these
documents or references ("herein cited references"), as well as
each document or reference cited in each of the herein cited
references (including any manufacturer's specifications,
instructions, etc.), is hereby expressly incorporated herein by
reference. Documents incorporated by reference into this text or
any teaching therein can be used in the practice of this invention.
Documents incorporated by reference into this text are not admitted
to be prior art. Furthermore, author or inventors on documents
incorporated by reference into this text are not to be considered
to be "another" or "others" as to the present inventive entity and
vice versa, especially where one or more authors or inventors on
documents incorporated by reference into this text are an inventor
or inventors named in the present inventive entity.
FIELD OF THE INVENTION
The present invention relates to a three-dimensional tissue
engineered system, and compositions obtained therefrom, wherein
individual layers of the system comprise channels having multiple
cell types (e.g., organ-specific cells and a vascular supply)
divided by membrane.
BACKGROUND OF THE INVENTION
Methods of achieving organ substitution involve three broad classes
of approaches. In the first, replacement organs are realized by the
construction of electromechanical devices, such as the recently
developed, wholly implantable mechanical replacement heart. A
second alternative involves the use of xenotransplantation, or
animal organs, rather than human donor organs. The third general
category of providing replacement function for tissues and organs
involves the rapidly emerging field of tissue engineering.
The principal disadvantages of mechanical devices and
xenotransplantation involve the challenges of integrating these
devices and tissues within the host. In the former case, mechanical
devices utilize materials that are foreign to the host and
therefore engender processes such as inflammation and clotting.
Additionally, mechanical devices are inherently temporary in
nature, since they require artificial power supplies, control
circuitry and other features that can never fully integrate into a
natural system. In the case of xenotransplantation, the human
immune system is designed to reject cells and tissues from foreign
species and therefore, immune system suppression and its inherent
risks remain a challenge. Additional risks involve the transmission
of genetic viruses from the donor animal to the host.
Tissue engineers have taken several approaches to generate
replacement tissues and organs in the laboratory. Generally,
autologous tissue (from cells taken from the organ recipient) are
seeded onto a scaffold and expanded in culture. This scaffold must
be biologically compatible to avoid inflammatory responses and
rejection of the implanted device, and may be biodegradable so that
the artificial material bioresorbs, leaving only natural tissue.
Scaffold fabrication techniques include an array of polymer
processing techniques such as molding, casting, fiber mesh
fabrication, and solid freeform fabrication. All of these methods
lack the resolution necessary to fashion the finest features of the
organ, such as the capillaries, which predominate the circulatory
supply. More recent developments in microfabrication technology,
such as MEMS (MicroElectroMechariical Systems), which includes
silicon micromachining and polymer replica molding, have improved
construction of artificial tissue and organ scaffolds. Typically,
the resolution of these techniques is in the 10 nun-1-micron range,
well in the range of what is necessary to configure the highest
fidelity features of an organ.
Within the field of tissue engineering, two basic methods for
organizing cells into tissue structures and organs are being
pursued. For most tissues and organs, multiple cell types are
required; the most significant requirement in addition to the need
for replacement of specific organ function is the cellular
component of the vascular supply, which nourishes the tissue. One
such class of methods utilizes biochemical factors, chemical
gradients, growth factors and other chemical means to arrange
multiple cell types on a substrate. These chemical techniques may
involve the micropatterning of the scaffold surface for cell and
tissue engineering with surface chemistries, which enhance
adhesion, growth, alignment and other behaviors of specific cell
types.
The second broad class of methods utilizes precision loading of
specific cell types into separate microengineered compartments
within the tissue-engineered structure. Such an approach often
invokes microfluidic loading, either dynamically or statically, of
a network of channels or vessels connected to form a cell
compartment, with a semi-permeable barrier that physically
separates cells from all other compartments. In sequential fashion,
each compartment of a bilayer structure is loaded with the specific
cell type, and communication between compartments is controlled by
porous or non-porous barriers (J. T. Borenstein, et al. Proc. 12th
Int'l. Conf. Solid State Sensors, Actuators and Microsystems
(Transducers 2003), 1754-7 (2003)). Properties of the barrier
material are governed by the requirements of the specific cells and
tissues in adjacent compartments. For instance, in the case of
organ-specific cells such as hepatocytes contained in a compartment
adjacent to the endothelial cells comprising the vascular supply,
the barrier material, or membrane, must physically separate the
cell types from adjacent compartments during cell seeding, but must
readily enable the transfer of oxygen, nutrients and waste products
between the two compartments.
This microfabrication process is inherently two-dimensional in
nature, and one way to construct a three-dimensional tissue
engineered device is to stack multiple layers of cell sheets, with
microfabricated membranes interspersed between these layers. The
interspersed membranes contain pores that govern the transport
properties of the film; the pore size, porosity and permeability of
the membrane are controlled to provide the appropriate behavior for
the desired application. The stacking process proceeds as follows:
a microfabricated polymer film imprinted with a pattern for the
compartment containing organ-specific cells, such as hepatocytes,
is placed at the bottom of the stack. Next, a membrane with
controlled transport properties is placed over the compartment, and
bonded to the compartment layer. Next, a microfabricated polymer
film with vascular channels imprinted (face down) is placed over
the membrane, and bonded to it. In this manner, cells loaded into
the lower compartment communicate with the vascular channels
located above it by transport through the membrane.
Three-dimensional integration of this assembly is achieved by
situating vertical through-holes within each of the layers, thus
forming "pipes" along the z-axis. Pipes for the organ-specific
compartment are connected laterally to the compartments within each
organ-specific layer, but are separated from the pipes associated
with integration of the vascular layers.
One of the principal drawbacks of the foregoing approach involves
the restrictions on the design of organ structures. For instance,
the stacking approach described above results in capillary beds
that are oriented laterally within the polymer film containing the
vascular network but does not allow for vertically oriented blood
vessels other than the inflow and outflow pipes integrating the
entire network. This restriction results in a limited density of
capillaries within the three-dimensional structure; the ratio of
small blood vessels to large vessels is not nearly as high as it is
in physiological systems.
Thus, there remains a need in the art for devices and methods that
can replicate the requisite features of the organ it is replacing,
such as the fluid dynamics of the vascular supply and other organ
structures.
SUMMARY OF THE INVENTION
To address obstacles in the art, compositions and methods of the
invention provide a three-dimensional system comprising repeating
layers, wherein an aggregate of cell types can be contained in a
single layer.
The present invention differs from former approaches, which require
three separate layers, one for the vascular network, one for the
membrane, and one for the organ-specific (e.g., parenchymal cells),
in order to build a single "unit cell" for stacking. The present
invention incorporates each of these three layer functions into a
single layer, integrated with adjacent layers, greatly reducing the
complexity of the device fabrication. Former methods also require
that vascular and parenchymal cells be arranged on separate polymer
films, separated by a semipermeable membrane in the z-axis. Systems
of the present invention divide the vascular and parenchymal cells
with micropores or nanopores connecting the cell compartments
within the same layer. As a result, the total volume of polymer is
reduced by as much as a factor of three, since roughly the same
number of total cells are contained within one polymer film rather
than the three layers making up each organ subunit.
Accordingly, in one embodiment, the present invention provides a
three-dimensional system comprising at least two layers, wherein
each layer comprises channels divided longitudinally into two
compartments by a centrally positioned membrane. Each compartment
can comprise a different cell type (e.g., organ-specific cells in
one compartment and a vascular supply in the second compartment).
As a result, an aggregate of cell types can be contained in a
single layer, which is then integrated into a multi-layer
system.
In a further embodiment, cell types on each side of the membrane
can align vertically with the same cell type contained in the
adjacent layer.
Each layer of the system will have a support element, comprising a
surface in which the channels are formed. The support element can
comprise a mold, and/or a polymer scaffold. The support element can
be made of nondegradable polymers such as PolyDiMethylSiloxane
(PDMS), PolyMethylMethacrylate (PMMA), or can comprise
biodegradable materials such as PolyCaproLactone (PCL), or
biorubber, but the invention is not so limited.
In yet another embodiment, a sealant can be placed over the
channels. The sealant can be made of the same or different material
used to form the support element. The membrane can be
semi-permeable and can function as a filter. The membrane can be
made of a biologically compatible, nondegradable material such as
PolyDiMethylSiloxane (PDMS), PolyMethylMethacrylate (PMMA),
PolyEtherSulfone (PES), PolyCarbonate (PC), or from a degradable
material such as polylactide-co-glycolide (PLGA), PolyCaproLactone
(PCL) or Biorubber, but the invention is not so limited. Each layer
can further comprise connections for inflow and outflow. In another
embodiment, the membrane comprises nano-scale pores through which
flow between the compartments is conducted. Pores can range from a
few nanometers to a few microns in diameter, depending upon the
filtration requirements and the fabrication process used to produce
the membranes. Preferably, the pores are between 100 nanometers and
2 microns. Pores can also be less than 100 nanometers.
In yet another embodiment, the membrane can be fortified by a solid
material added to the system. The solid material can incorporate
into the membrane, providing additional support, or altering the
geometry or transport properties of the pores in a controlled way.
The solid material can be a porous solid, including but not limited
to, collagen (e.g., Matrigel.TM.), fibronectin, laminin, or
self-assembling peptides, but the invention is not so limited. In
one embodiment, the solid material can incorporate into the
nano-pore, to further subdivide the area in which flow between
compartments takes place.
In yet another embodiment, the membrane divides non-vascular cells
from cells comprising a vascular network. Each side is referred to
herein as a "compartment." Non-vascular cell types can include
parenchymal cells. Parenchymal cells include, but are not limited
to smooth or skeletal muscle cells, myocytes, fibroblasts,
chondrocytes, adipocytes, fibromyoblasts, ectodermal cells,
including ductile and skin cells, liver cells (e.g., hepatocytes,
kupffer cells), kidney cells, pancreatic islet cells, cells present
in the intestine, nerve cells, osteoblasts and other cells forming
bone or cartilage, and hematopoietic cells (e.g., mast cells).
In yet another embodiment, the compartments of a channel can be
interconnected within a single layer by structures comprising
bridges. Bridges between compartments connect one section of a
compartment to another compartment or another section of the same
compartment, within a single layer. Bridges can connect
compartments having same cell types, or compatible cell types.
Compatible cell types are those which provide support for primary
cell types (e.g., organ specific cell types), such as stromal or
connective cell types. Heterotypic interactions between fibroblasts
and hepatocytes have been shown to be critical for hepatocyte
viability, and therefore, these cells are an example of compatible
cell types.
In yet another embodiment, three-dimensional systems of the
invention comprise a device. The device can be extracorporeal or
implantable. Specific applications include use of the device as a
biodegradable scaffold in methods of tissue engineering; use as a
biodegradable or biologically compatible life assist; use as a
biohybrid artificial organ or tissue; and use in drug delivery.
Thus, the invention provides scalable techniques for producing
organs, or portions thereof, large enough to transplant into a
subject, such as animal recipients, typically vertebrate
recipients, and preferably human recipients. A "subject" is a
vertebrate, preferably a mammal, and most preferably a human.
Mammals include, but are not limited to, humans, farm animals,
sport animals, and pets (e.g., dogs, cats). One of skill in the art
can readily vary the parameters of the methods described herein to
accommodate hosts or subjects of variable size and species,
including but not limited to, humans of any age.
In yet another embodiment, the three-dimensional systems of the
invention can be used to carry out pharmacological studies of
candidate drugs, to test for toxicity and efficacy of lead
compounds or existing drugs, to replace suspect animal models and
expensive clinical trials.
As used herein, the terms "comprises", "comprising", and the like
can have the meaning ascribed to them in U.S. Patent Law and can
mean "includes", "including" and the like.
These and other embodiments are disclosed or are obvious from and
encompassed by, the following Detailed Description.
BRIEF DESCRIPTION OF THE FIGURES
The following Detailed Description, given by way of example, but
not intended to limit the invention to specific embodiments
described, may be understood in conjunction with the accompanying
Figures, incorporated herein by reference, in which:
FIG. 1 depicts a schematic of a former method for generating
engineered tissues using co-culture. The rose-colored layer
represents vascular endothelial cell channels, which are separated
from the semi-transparent block containing organ-specific cells by
the gray semi-permeable membrane. Cell placement is achieved by
separating channel networks for each cell type and filling them
sequentially and separately.
FIG. 2 depicts an alternate view of the former method for producing
tissue-engineered constructs using stacking of interspersed layers
of parenchymal cells, membranes and vascular cells.
FIG. 3 depicts the simplest subunit of the tissue-engineered
system. A porous membrane, all within a single layer, separates a
vascular vessel and parenchymal vessel.
FIG. 4 depicts an overhead view of a membrane created by leaving
nano-pore gaps in the wall between the two compartments (arrows
denote flow across the membrane).
FIG. 5 depicts a cross-sectional view of a nano-scale pore between
two compartments (arrow denotes flow across the membrane).
FIG. 6 depicts a cutaway view of a membrane constructed using a
combination of nano-scale and micron-scale techniques. Nano-scale
techniques allow fine control of channel dimensions while
micron-scale techniques add mechanical support posts.
FIG. 7 depicts the addition of acid-solubilized collagen or a
self-assembling peptide flowed into network aggregates in
mechanical pores to enhance filtration.
FIG. 8 depicts the parenchymal compartment bridges over the
vascular, to be placed at any intersection between the vascular and
parenchymal compartments.
FIG. 9 depicts the bottom layer of the tissue-engineered system.
White areas are unetched; gray areas are full-depth etches, and
blue areas are nano-scale etches for pores. Crosses connected to
network are connection sites for vertical vessels.
FIG. 10 depicts the upper layer of the tissue-engineered
system.
FIG. 11 depicts a complete design, with the upper layer stacked
upon the lower layer. Fluid flows between layers via vertical
vessels are denoted by arrows.
FIG. 12 depicts a flow schematic of the tissue engineered system.
The vascular network and porous membrane exist only on the bottom
layer. The parenchymal network exists on the upper and lower layer
and has vertical interconnects between the two layers.
FIG. 13 depicts a tiling pattern used to create large networks.
Tiling can extend arbitrarily far in either direction to create
networks of any size.
FIG. 14 depicts a schematic illustrating the advantage in
resolution obtained by generating pores with the narrow dimension
oriented in the z-axis rather than in the plane of the layer.
FIG. 15 depicts scanning electron microscope images of J-Pore
design.
FIG. 16 depicts a schematic of the PolyLactide-co-Glycolide (PLGA)
melt processing using PolyDiMethylSiloxane (PDMS) molds.
FIG. 17 depicts a melt-processing apparatus. The hotplate is for
temperature control; Instron is used for application of controlled
force; and the polymer pellets-PDMS-rigid plate stack are used for
compression molding.
FIG. 18 depicts light microscopy images of pores between channels
in a PLGA device. FIG. 18 A) shows that pores and channels are
maintained during the bonding process. FIG. 18 B) shows pores out
of focus, while channels are in focus. Pores become more difficult
to detect after bonding. They are clearest when the rest of the
design features are out of focus.
FIG. 19 depicts light microscopy images of 40-llm wide channels and
pores occluded with red fluorescent beads.
FIG. 20 depicts light microscopy images of 20-jjm-wide channels.
Pores between channels were maintained in the left half of the
picture and occluded in the right half. Red fluorescent beads of I
tm in diameter were flowed through the upper channel.
FIG. 21 depicts light microscopy images of 40-.mu.m-wide channels.
Pores between channels were maintained and 6-.mu.m red fluorescent
beads were flowed through the upper channel.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a three-dimensional system
comprising at least two layers, wherein each layer comprises
channels divided longitudinally into two compartments by a
centrally positioned membrane. Each compartment can comprise a
different cell type (e.g., organ-specific cells in one compartment
and a vascular supply in the second compartment). As a result, an
aggregate of cell types can be contained in a single layer, which
is then integrated into a multi-layer system.
Each layer of the system will have a support element, comprising a
surface in which the channels are formed. The support element can
be made of f nondegradable polymers such as PolyDiMethylSiloxane
(PDMS), PolyMethylMethacrylate (PMMA), or can comprise
biodegradable materials such as PolyCaproLactone (PCL), or
biorubber, but the invention is not so limited.
The support element can comprise a mold. A two-dimensional (x, y)
mold is fabricated using high-resolution molding processes, such as
micromachined wafer technology, thick photoresist processes, or
other techniques, to create a patterned of micromachined, small
dimensioned channels ("microchannels"), such that the micromachined
channels are connected for the circulation of fluid in the
multilayer apparatus. Microchannels can comprise, for example,
open-faced channels defined by walls extending from a
tissue-defining surface into a substrate. The invention also
encompasses a substrate wherein the tissue-defining surface
comprises an open-faced compartment defined by walls extending from
a tissue-defining surface into a substrate.
Manufacture of Molds and Polymer Scaffolds
Each layer of the system will have a support element that can
comprise a mold. For purposes of this invention a "mold" is a
device on the surface of which the branching structure of the
microchannels is etched or formed. Fabrication of a mold begins by
selection of an appropriate substrate. The choice of a substrate
material is guided by many considerations, including the
requirements placed on the fabrication process by the desired mold
dimensions, the desired size of the ultimate template, and the
surface properties of the wafer and their interaction with the
various cell types, extracellular matrix ("ECM") and polymeric
backbone. Also important are the thermal properties, such as the
glass transition temperature (Tg), which must be high enough so
that the network of pores in the mold does not collapse upon
solvent removal if a thermal process is used to process the
layers.
Molds of the present invention can comprise a variety of materials,
including, but not limited to, inert materials such as silicon,
polymers such as polyethylene vinyl acetate, polycarbonate, and
polypropylene, and materials such as a ceramic or material such as
hydroxyapatite. In particular, the mold can comprise from metals,
ceramics, semiconductors, organics, polymers, and composites.
Representative metals and semiconductors include pharmaceutical
grade stainless steel, gold, titanium, nickel, iron, gold, tin,
chromium, copper, alloys of these or other metals, silicon, silicon
dioxide. These materials are either inherently suitable for the
attachment and culture of animal cells or can be made suitable by
coating with materials described herein to enhance cell attachment
and culture (e.g. gelatin, matrigel, vitrogen and other tissue
culture coatings known in the art).
MEMS replica molding can be used to make a "polymer scaffold" for
seeding cells. In this method, a mold is made as described herein,
preferably of silicon, and is then used as a template on which a
polymeric material is cast. Optionally, the polymer scaffold can
then be peeled away from the mold and seeded with cells.
A "tissue-defining surface" is the surface of a mold or a polymer
scaffold, and a "substrate" is the mold or polymer scaffold
itself.
The term "polymer" includes polymers and monomers that can be
polymerized or adhered to form an integral unit. The polymer can be
non-biodegradable or biodegradable, typically via hydrolysis or
enzymatic cleavage. Biodegradable matrices are not typically
preferred to construct molds, since they are not implanted and are
preferably reusable. For implantation, polymer scaffolds are
preferably used, more preferably biodegradable polymer
scaffolds.
Preferably, the biodegradable polymer scaffold comprises
biodegradable elastomers formed from hydrolyzable monomers as
described in Wang et al, Nature Biotech 20, 602 (2002), the
contents of which are incorporated herein by reference. These
biodegradable elastomers are analogous to vulcanized rubber in that
crosslinks in a three-dimensional network of random coils are
formed. These biodegradable elastomers are hydrolyzed over time,
preferably within 60 days.
Polymer material for implantation should be selected for
biocompatibility. Any degradation products should also be
biologically compatible. Relatively high rigidity is advantageous
so that the polymer scaffold can withstand the contractile forces
exerted by cells growing within the mold. A biologically compatible
degradable polymer and its degradation products are non-toxic
toward the recipient.
The term "biodegradable" refers to materials that are bioresorbable
and/or degrade and/or break down by mechanical degradation upon
interaction with a physiological environment into components that
are metabolizable or excretable, over a period of time from minutes
to three years, preferably less than one year, while maintaining
the requisite structural integrity. As used in reference to
polymers, the term "degrade" refers to cleavage of the polymer
chain, such that the molecular weight stays approximately constant
at the oligomer level and particles of polymer remain following
degradation.
The term "completely degrade" refers to cleavage of the polymer at
the molecular level such that there is essentially complete loss of
mass. The term "degrade" as used herein includes "completely
degrade" unless otherwise indicated.
Materials suitable for polymer scaffold fabrication include, but
are not limited to, poly-dimethyl-siloxane (PDMS),
poly-glycerol-sebacate (PGS), polylactic acid (PLA), poly-L-lactic
acid (PLLA), poly-D-lactic acid (PDLA), polyglycolide, polyglycolic
acid (PGA), polylactide-co-glycolide (PLGA), polydioxanone,
polygluconate, polylactic acid-polyethylene oxide copolymers,
modified cellulose, collagen, polyhydroxybutyrate,
polyhydroxpriopionic acid, polyphosphoester, poly (alpha-hydroxy
acid), polycaprolactone, polycarbonates, polyamides,
polyanhydrides, polyamino acids, polyorthoesters, polyacetals,
polycyanoacrylates, degradable urethanes, aliphatic
polyesterspolyacrylates, polymethacrylate, acyl substituted
cellulose acetates, non-degradable polyurethanes, polystyrenes,
polyvinyl chloride, polyvinyl flouride, polyvinyl imidazole,
chlorosulphonated polyolifins, polyethylene oxide, polyvinyl
alcohol, Teflon.RTM., nylon silicon, and shape memory materials,
such as poly (styrene-block-butadiene), polynorbornene, hydrogels,
metallic alloys, and oligo (s-caprolactone) diol as switching
segment/oligo (p-dioxyanone) diol as physical crosslink. Other
suitable polymers can be obtained by reference to The Polymer
Handbook, 3rd edition (Wiley, N.Y., 1989). Combinations of these
polymers may also be used.
Polylactide-co-glycolides (PLGA), as well as polylactides (PLA) and
polyglycolides (PGA) have been used to make biodegradable implants
for drug delivery. See U.S. Pat. Nos. 6,183,781 and 6,733,767 and
references cited therein, the contents of which are specifically
incorporated herein by reference. The ratio of lactide to glycolide
of the poly (lactide-co-glycolide) copolymer can be, for example,
75:25, 60:40, 85:15 or 65:35. Biodegradable materials have been
developed for use as implantable prostheses, as pastes, and as
templates around which the body can regenerate various types of
tissue. Polymers that are both biologically compatible and
resorbable in vivo are known in the art as alternatives to
autogenic or allogenic substitutes. In a preferred embodiment,
polymers are selected based on the ability of the polymer to elicit
the appropriate biological response from cells, for example,
attachment, migration, proliferation and gene expression.
Solvents for most of the thermoplastic polymers are known, for
example, methylene chloride or other organic solvents. Organic and
aqueous solvents for protein and polysaccharide polymers are also
known. The binder can be the same material as is used in
conventional powder processing methods or can be designed to
ultimately yield the same binder through chemical or physical
changes that occur as a result of heating, photopolymerization, or
catalysis.
Properties of the mold and/or polymer scaffold surface can be
manipulated through the inclusion of materials on the mold or in
polymer scaffold material which alter cell attachment (for example,
by altering the surface charge or structure), porosity, flexibility
or rigidity (which may be desirable to facilitate removal of tissue
constructs). Moreover, advances in polymer chemistry can aid in the
mechanical tasks of lifting and folding as well as the biologic
tasks of adhesion and gene expression. A "release layer" can be
deposited onto the molds. The release layer can comprise materials
such as, but not limited to, teflon-like layers generated by C4F8
plasma treatment. The release layer can be deposited in solid,
liquid or vapor phase. Its main function is to reduce adhesion of
the polymer replica to the master mold.
For example, molds can be coated with a unique
temperature-responsive polymer, poly-N-isopropyl acrylamide
(PNIPAAm), which demonstrates a fully expanded chain conformation
below 32.degree. C. and a collapsed, compact conformation at high
temperatures. When grafted onto surfaces of silicon wafers using
electron beam irradiation, it can be used as a temperature switch
for creating hydrophilic surfaces below 32.degree. C. and
hydrophobic surfaces above 32.degree. C. Since PNIPAAm is insoluble
in water over the lower critical solution temperature (LCST about
32.degree. C.) and reversibly solubilized below the LCST, cells
detach from the substratum by simply lowering the temperature below
the LCST. One of skill in the art can (1) engraft the polymer on
silicon wafers that are pre-coated with polystyrene or (2) engraft
the polymer on silicon wafers whose surface is first modified by
vinyl-trichlolorosilane. Either of these techniques will ensure
that the polymer is better integrated and conjugated to its
substratum (polystyrene in the former case and vinyl groups in the
later case) so that it can serve as an effective thermal switch,
useful in reversing cell attachment and detachment as a single
contiguous layer of cells without the usual cell damage.
Another system for promoting both cellular adhesion and lifting of
cells as intact sheets can involve the use of RGD (Arg-Gly-Asp)
peptides. The RGD sequence is part of the domain within the
fibronectin molecule that endows it with the ability to interact
with adhesion molecules present on the cell surface of fibroblasts.
Fibronectin itself is a well-characterized extracellular,
structural glycoprotein which interacts strongly with other
extracellular matrix molecules and which causes the attachment and
spreading of most cells. This function of the fibronectin molecule
is localized primarily to the RGD sequence. One of skill in the art
can synthesize RGD peptides with a structural backbone of PMMA that
has an RGD peptide sequence at its tips, bound to one another with
the intermediate layering of polyethylene oxide. This allows
differential cell adhesion in only selected areas and not others.
Once the tissue of desired quality is formed, release of this
intact monolayer of tissue from its substratum is straightforward;
it requires only the addition of soluble RGD to the culture medium
to act as a competitive substrate to the insolubilized RGD
substrate on the silicon mold surface.
In some embodiments, attachment of the cells to the mold and/or
polymer scaffold is enhanced by coating the substrate with
compounds such as basement membrane components, agar, agarose,
gelatin, gum arabic, types I, II, III, IV, and V collagen,
fibronectin, laminin, glycosaminoglycans, matrigel, vitrogen,
mixtures thereof, and other materials known to those skilled in the
art of cell culture.
Thus, by the methods of the invention, cells can be grown on molds
that are uncoated or coated as described herein, depending upon the
material used for mold construction. Alternatively, cells can be
grown on polymer scaffolds made by replica molding techniques.
Micromachining and Chemical Processing of Silicon and Other Mold
Materials
Molds can be made by creating small mechanical structures in
silicon, metal, polymer, and other materials using microfabrication
processes. These microfabrication processes are based on
well-established methods used to make integrated circuits and other
microelectronic devices, augmented by additional methods developed
by workers in the field of micromachining.
Microfabrication processes that can be used in making the molds
disclosed herein include lithography; etching techniques, such as
lasers, plasma etching, photolithography, or chemical etching such
as wet chemical, dry, and photoresist removal; or by solid free
form techniques, including three-dimensional printing (3DP),
stereolithography (SLA), selective laser sintering (SLS), ballistic
particle manufacturing (BPM) and fusion deposition modeling (FDM);
by micromachining; thermal oxidation of silicon; electroplating and
electroless plating; diffusion processes, such as boron,
phosphorus, arsenic, and antimony diffusion; ion implantation; film
deposition, such as evaporation (filament, electron beam, flash,
and shadowing and step coverage), sputtering, chemical vapor
deposition (CVD), epitaxy (vapor phase, liquid phase, and molecular
beam), electroplating, screen printing, lamination or by
combinations thereof. See Jaeger, Introduction to Microelectronic
Fabrication (Addison-Wesley Publishing Co., Reading Mass. 1988);
Runyan, et al., Semiconductor Integrated Circuit Processing
Technology (Addison-Wesley Publishing Co., Reading Mass. 1990);
Proceedings of the IEEE Micro Electro Mechanical Systems Conference
1987-1998; Rai-Choudhury, ed., Handbook of Microlithography
Micromachining & Microfabrication (SPIE Optical Engineering
Press, Bellingham, Wash. 1997). The selection of the material that
is used as the mold determines how the surface is configured to
form the branching structure. The following methods are preferred
for making molds.
Typically, micromachining is performed on standard bulk single
crystal silicon wafers of a diameter ranging between about 50 and
300 millimeters (mm), preferably approximately 60 mm, and of
thickness ranging between about 200 and 1200 um. These wafers can
be obtained from a large number of vendors of standard
semiconductor material, and are sawn and polished to provide
precise dimensions, uniform crystallographic orientation, and
highly polished, optically flat surfaces.
Wafers made from pyrex borosilicate or other glasses can also be
procured and inserted into micromachining processes, with
alternative processes used to etch the glassy materials.
The geometry of the mold, in particular the number of different
feature depths required, is the major factor determining the
specific process sequence. The simplest case is that of a single
depth dimension for the mold. Specifically, for a silicon
substrate, one type of process sequence is as follows: first, the
silicon wafer is cleaned, and a layer of photosensitive material is
applied to the surface. Typically, the layer is spun on at a high
revolution rate to obtain a coating of uniform thickness. The
photoresist is baked, and the wafer is then exposed to ultraviolet
or other short-wavelength light though a semi-transparent mask.
This step can be accomplished using any one of several masking
techniques, depending on the desired image resolution. The resist
is then developed in appropriate developer chemistry, and the wafer
is then hard-baked to remove excess solvent from the resist. Once
the lithographic process has been completed, the wafer can be
etched in a plasma reactor using one of several possible
chemistries. Etching serves to transfer the two-dimensional pattern
into the third dimension: a specified depth into the wafer. Plasma
parameters are determined by the desired shape of the resulting
trench (semi-circular, straight-walled profile, angled sidewall),
as well as by the selectivity of the etchant for silicon over the
masking photoresist. Once the etching has been completed, the
photoresist can be removed and the wafer prepared for use in the
tissue molding process.
Increased flexibility in the geometry of wafer mold can be obtained
by inserting additional cycles of masking and etching. This
modification provides the opportunity to machine channels of
varying depths into the wafer mold. To design a mold that is
suitable for the culturing of endothelial cells, increased
flexibility is very important due to the need for vascular branches
with different diameters. The techniques can be extended to provide
as many additional layers and different depths as are desired. In
addition, these techniques can be used to create secondary patterns
within the pattern of microchannels. For example, it may be
advantageous to have wells within the microchannels for culturing
additional cell types such as feeder cells. The pattern of
microchannels also can be designed to control cell growth, for
example, to selectively control the differentiation of cells.
Another type of mold is fabricated simply through photolithography
with no etching. The standard photoresist for this type of process,
known as SU-8, is an epoxy resin negative resist material designed
for use in conventional mask aligners. Resin viscosity can be
adjusted to provide an enormous range of resultant thicknesses,
providing layers as thin as 2 microns but as thick as 1 mm for
various applications. Challenges involving film adhesion and
cracking can be addressed by suitable process modifications.
One highly advantageous aspect of high aspect ratio
photolithography is the ability to produce multiple pattern heights
in the film, simply by using multiple exposures followed by a
single development step, or other straightforward process
variations. Feature geometry, such as the curvature of sidewalls at
the top and bottom of structures, can be controlled by varying the
baking parameters during processing. Subsequent adhesion of polymer
films during replica de-molding is often low enough to enable ease
of release, but plasma deposition equipment may be used to apply a
thin mold release layer as required.
Glass and polymeric wafer molds can be fabricated using a similar
sequence, but the actual process can be modified by the addition of
an intervening masking layer, since etchants for these materials
may attack photoresist as well. Such intervening materials simply
function to transfer the pattern from the photoresist to interlayer
and then on to the wafer below. For silicon etched in one of
several wet chemistries, an intervening layer may also be
necessary.
Molds formed of silicon dioxide can be made by oxidizing the
surface of the silicon mold forms, rather than depositing a metal
and then etching away the solid needle forms to leave the hollow
silicon dioxide structures. In one embodiment, hollow, porous, or
solid molds are provided with longitudinal grooves or other
modifications to the exterior surface of the molds.
Polymeric molds can also be made using microfabrication. For
example, the epoxy molds can be made as described above, and
injection molding techniques can be applied to form the structures.
These micromolding techniques are relatively less expensive to
replicate than the other methods described herein.
Three dimensional printing (3DP) is described by Sachs, et al.,
Manufacturing Review 5, 117-126 (1992) and U.S. Pat. No. 5,204,055
to Sachs, et al. 3DP is used to create a solid object by ink-jet
printing a binder into selected areas of sequentially deposited
layers of powder. Each layer is created by spreading a thin layer
of powder over the surface of a powder bed. The powder bed is
supported by a piston, which descends upon powder spreading and
printing of each layer (or, conversely, the ink jets and spreader
are raised after printing of each layer and the bed remains
stationary). Instructions for each layer are derived directly from
a computer-aided design (CAD) representation of the component. The
area to be printed is obtained by computing the area of
intersection between the desired plane and the CAD representation
of the object. The individual sliced segments or layers are joined
to form the three-dimensional structure. The unbound powder
supports temporarily unconnected portions of the component as the
structure is built but is removed after completion of printing.
SFF methods other than 3DP that can be utilized to some degree as
described herein are stereo-lithography (SLA), selective laser
sintering (SLS), ballistic particle manufacturing (BPM), and fusion
deposition modeling (FDM). SLA is based on the use of a focused
ultra-violet (UV) laser that is vector scanned over the top of a
bath of a photopolymerizable liquid polymer material. The UV laser
causes the bath to polymerize where the laser beam strikes the
surface of the bath, resulting in the creation of a first solid
plastic layer at and just below the surface. The solid layer is
then lowered into the bath and the laser generated polymerization
process is repeated for the generation of the next layer, and so
on, until a plurality of superimposed layers forming the desired
apparatus is obtained. The most recently created layer in each case
is always lowered to a position for the creation of the next layer
slightly below the surface of the liquid bath. A system for
stereolithography is made and sold by 3D Systems, Inc., of
Valencia, Calif., which is readily adaptable for use with
biologically compatible polymeric materials. SLS also uses a
focused laser beam, but to sinter areas of a loosely compacted
plastic powder, the powder being applied layer by layer. In this
method, a thin layer of powder is spread evenly onto a flat surface
with a roller mechanism. The powder is then raster-scanned with a
high-power laser beam. The powder material that is struck by the
laser beam is fused, while the other areas of powder remain
dissociated. Successive layers of powder are deposited and
raster-scanned, one on top of another, until an entire part is
complete. Each layer is sintered deeply enough to bond it to the
preceding layer. A suitable system adaptable for use in making
medical devices is available from DTM Corporation of Austin,
Tex.
BPM uses an ink-jet printing apparatus wherein an ink-jet stream of
liquid polymer or polymer composite material is used to create
three-dimensional objects under computer control, similar to the
way an ink-jet printer produces two-dimensional graphic printing.
The mold is formed by printing successive cross-sections, one layer
after another, to a target using a cold welding or rapid
solidification technique, which causes bonding between the
particles and the successive layers. This approach as applied to
metal or metal composites has been proposed by Automated Dynamic
Corporation of Troy, N.Y. FDM employs an x-y plotter with a z
motion to position an extrudable filament formed of a polymeric
material, rendered fluid by heat or the presence of a solvent. A
suitable system is available from Stratasys, Incorporated of
Minneapolis, Minn.
The design of the channels in the mold can be constructed by a
number of means, such as fractal mathematics, which can be
converted by computers into two-dimensional arrays of branches and
then etched onto wafers. Also, computers can model from live or
preserved organ or tissue specimens three-dimensional vascular
channels, convert to two-dimensional patterns and then help in the
reconversion to a three-dimensional living vascularized structure.
Techniques for producing the molds include techniques for
fabrication of computer chips and microfabrication technologies.
Other technologies include laser techniques.
Design of Apparatus
The present invention provides a three-dimensional system
comprising at least two layers, wherein each layer comprises
channels divided longitudinally into two compartments by a
centrally positioned membrane. Each compartment can comprise a
different cell type (e.g., organ-specific cells in one compartment
and a vascular supply in the second compartment). As a result, an
aggregate of cell types can be contained in a single layer, which
is then integrated into a multi-layer system.
A diagram showing the spatial relationship of parenchymal and
vascular cells is shown in FIG. 3, where a permeable membrane is
depicted, separating the two cell layers in a single channel. The
membrane vertically transects the center of each channel, dividing
cell types as desired into two compartments. FIG. 3 represents the
simplest subunit of a system of the present invention.
The membrane can comprise a wall of polymer having pores to allow
transport from one compartment to the other. The pores can be
constructed in at least two ways. Leaving gaps in the polymer wall,
as shown in FIG. 4, can create pores on the micron-scale. FIG. 4
represents one embodiment, wherein leaving gaps in the wall between
the two compartments can create the membrane. Smaller nano-scale
pores in the membrane (e.g., less than 100 nm, 100-200 nm, 200-800
nm) can be created by utilizing the fine control of the wafer
fabrication methods in the direction perpendicular to the plane of
the wafer. This method creates a membrane as in FIG. 5, which
depicts a cross-sectional view of a nano-scale pore between two
compartments.
These two approaches for creating channels can be combined,
effectively adding posts in the nano-scale gap to increase support.
A membrane incorporating both embodiments is shown in FIG. 6, which
shows a cutaway view of the membrane constructed using a
combination of nano-scale and micron-scale techniques. Nano-scale
techniques allow fine control of channel dimensions, while
micron-scale techniques add mechanical support posts.
A sealant can be placed over the channels. The sealant can be made
of the same or different material used to form the support
element.
Filtration of solutes can be further achieved by addition of an
aggregated porous solid to the pores to enhance filtration by
restricting the flow of large molecules (FIG. 7). Materials that
can be used as aggregated porous solids include, but are not
limited to, acid-solubilized collagen or self-assembling peptides.
The solid material can incorporate into the membrane, providing
additional support, or altering the geometry or transport
properties of the pores in a controlled way. The solid material can
be a porous solid, including but not limited to, collagen (e.g.,
Matrigel.TM.), fibronectin, laminin, or self-assembling peptides,
but the invention is not so limited. In one embodiment, the solid
material can incorporate into the nano-pore, to further subdivide
the area in which flow between compartments takes place.
Numerous subunits can be connected to create complete vascular and
parenchymal tissue-engineered network. The compartments can be
interconnected within a single layer by structures comprising
bridges. The vascular and parenchymal compartments should not
intersect, so wherever they cross, the parenchymal compartment can
bridge over the vascular compartment, as shown in FIG. 8. Bridges
between compartments connect one section of a compartment to
another compartment or another section of the same compartment,
within a single layer. Bridges may optionally have pores as well.
Bridges can connect compartments having same cell types, or
compatible cell types. Compatible cell types are those which
provide support for primary cell types (e.g., organ specific cell
types), such as stromal or connective cell types. For example,
fibroblasts provide support hepatocytes, and are therefore a
compatible cell type.
Fabrication of a permeable membrane that is integrated within the
channels can be carried out using techniques known in the art
(Martin et al. (2001) Biomedical Microdevices, 3 (2): 97-108; Leoni
et al., (2004) Advanced Drug Delivery Reviews, 56 (2) pp. 211-229).
Using these methods, the system is constructed by controlling the
thickness of layers in the z-dimension. Typically, nanoscale
features (e.g., channels, membrane pores) are constructed by
orienting the narrow dimension of the pore along the vertical or
z-axis direction. The ability to control the thickness of deposited
film is more than an order of magnitude (typically 4 nm) better
than control of the width of patterned features. Using these
techniques, the mold for the pores is formed by depositing a thin
sacrificial layer of controlled thickness on the surface of the
mold wafer. Next, the mold for the pores is patterned and machined
by photolithography and etching. The etching process is such that a
step is created between the mold wafer surface and the height of
the sacrificial layer. Finally, channels and other features are
etched or lithographically patterned into the mold.
Stacking Molds and/or Polymer Scaffolds to Achieve
Three-Dimensionality
Fastening or sealing of the polymeric mold layers is required to be
leakproof and support fluid pressures necessary for dynamic cell
seeding. Preferably, the layers are irreversibly bound before
implantation into the host. Depending on the composition of the
layered material, the layers can be sealed by solvent bonding;
reflow by heating (40.degree. C.); treating surface with oxygen
plasma; or by polymer flow at the surface. Biologically compatible
polymer materials maybe bonded together by plasma activation to
form sealed structures (Jo et al., SPIE 3877,222 (1999)). The basic
process results in bonded layers with channel architecture closely
resembling that obtained with silicon etched molds.
One common method used to seal micromachined wafers together is
anodic bonding, a technique based on the high concentration of
mobile ions in many glasses (Camporese, et al., IEEE Electron.
Device Lett. EDL 2, 61 (1981)). This process produces a permanent
seal; fracture testing of silicon-glass anodically bonded
interfaces produces a failure within the bulk of the glass.
Etched wafers may be bonded together, producing closed lumens
suitable for fluidic experiments. Alternatively, the multilayered
device described by the present invention can be configured such
that each of the layers has an alignment indentation on one surface
of the layer and an alignment protrusion on the opposing surface of
another layer. The alignment indentations can be shaped to mate
with the alignment protrusion, so that the layers are held
together.
To build up the mold and/or polymer scaffold layers by mechanical
assembly, the layers can be mechanically mated using biodegradable
or non-biodegradable barbs, pins, screws, clamps, staples, wires,
string, or sutures. (See, U.S. Pat. No. 6,143,293.) With this
mechanical assembly approach, each prefabricated section can
comprise different mold and/or polymer scaffold material and/or
different mold microstructures. Different sections of these can be
seeded with cells before assembly. Cells thus be can be embedded
into the mold or polymer scaffold by assembling sections around
these components. In addition, surface features on each mold, which
are readily fabricated, become part of the internal microstructure
(e.g., molded surface channels become conduits for cell infusion,
or for blood flow to stimulate angiogenesis). A surface feature on
an individual mold or polymer scaffold will become an internal
feature when another segment is assembled over it. For example,
surface features such as channels can be micromachined into a first
mold or polymer scaffold layer. When a second mold or polymer
scaffold layer is placed atop that first layer, the micromachined
surface feature becomes an internal feature of the apparatus.
Connections between layers are achieved by integrating
through-holes alongside the channel-like features in each layer.
Through-holes connect in a specified way to the channel network,
and connect with through-holes in the layers above and below.
Semi-Permeable Membrane
In the multi-layer systems of the invention, each layer comprises
one or more channels having multiple cell types divided
longitudinally by a centrally positioned membrane. A semi-permeable
membrane can be used to separate the cell types. Preferably, the
pore size of the membrane is smaller than the cell diameters, thus,
cells will not be able to pass through (i.e. a low permeability for
animal cells), while low molecular weight nutrients and fluids can
pass through (i.e. a high permeability for nutrients), thereby
providing adequate cell-to-cell signaling. Cell sizes vary but in
general, they are in the range of microns. For example, a red blood
cell has a diameter of 8 m. Preferably, the average membrane pore
size is on a submicron-scale to ensure effective screening of the
cells.
The membrane can be made of a biologically compatible,
nondegradable material such as PolyDiMethylSiloxane (PDMS),
PolyMethylMethacrylate (PMMA), PolyEtherSulfone (PES),
PolyCarbonate (PC), or from a degradable material such as PLGA,
PolyCaproLactone (PCL) or Biorubber, but the invention is not so
limited.
Semi-permeable membranes of the present invention comprise a wide
array of different membrane types and morphologies, which can be
classified as follows:
(1) Track-etched membranes consisting of cylindrical through-holes
in a dense polymer matrix. These membranes are typically made by
ion-etching; or
(2) Fibrous membranes made by various deposition techniques of
polymeric fibers. Production methods enable fibrous membranes to
have specific molecular weight cut-offs.
Track-etch type membranes are preferred, as they limit the fluid
motion in one direction. Preferably, fluid motion is in the
vertical direction. Fibrous membranes permit fluid motion both
laterally and vertically.
The development of an appropriate membrane will mirror the device
progression. Biologically compatible and non-degradable membranes
can be incorporated in microchannels that are made from poly
(dimethyl siloxane) (PDMS). Since PDMS is non-degradable, the
membranes do not need to be degradable either. However, degradable
membranes and materials for microchannels can also be used. There
exists a variety of commercial track-etched membranes with
well-defined pore sizes that can be used for this purpose. Care
must be taken to properly incorporate the membranes into the
existing microchannels without leaking. To this end, the membranes
can be bonded with either an oxygen plasma or a silicone-based
adhesive.
A small recession can be designed into the microchannels so that
the membrane can fit tightly therein.
In principle, membrane formation from polymers relies on
phase-phase separation. Polymer-solvent interactions are complex,
and polymer phase diagrams are significantly more complicated than
those for monomeric materials, e.g., metals. Phase separation can
be induced either by diffusion (diffusion-induced phase separation
or "DIPS") or by thermal means (thermal induced phase separation or
"TIPS").
A DIPS system comprises polymer, solvent and non-solvent. The
polymer solution is cast as a thin film and then immersed in a
coagulation bath containing the non-solvent. This process is
governed by the diffusion of various low molecular weight
components. The exchange of solvent and non-solvent between the
polymer solution and the coagulation bath leads to a change in the
composition in the film and phase separation is induced. After some
time, the composition of the polymer-rich phase reaches the glass
transition composition and the system solidifies. To avoid
macrovoid formation, a small amount of non-solvent can be mixed
with the polymer solution. In a preferred embodiment, the polymer
is polycaprolactone (PCL) and the separation system is
chloroform/methanol. Specifically, a polymer solution with a
concentration ranging from about 5-10% wt. is made. PCL is prepared
by dissolving it in chloroform at room temperature under gentle
stirring. Once the polymer has completely dissolved, a small amount
is placed on a clean mirror surface, and a membrane knife is used
to spread out a film with preset thickness. The thickness of the
film can be adjusted by changing the gap between the knife blade
and the minor surface. Once the film has been spread, the entire
mirror is immersed in a methanol bath. Phase separation occurs
almost instantaneously, but the film and minor are left in the
coagulation bath for up to about 10 minutes to lock in the
morphology. A typical membrane thickness is about 100 J. m, and the
pore size is on the order of about 1 (J, in, preferably between
about 0.01 and 20 um. Membrane morphology can be varied by altering
the composition/concentration of the polymer solution, the film
thickness, the components of the coagulation bath, and/or the
process conditions. One skilled in the art would understand how to
vary any one of these parameters to achieve the desired result.
A TIPS system comprises a thermal gradient to induce phase
separation. By choosing a polymer-solvent system that is miscible
at high temperatures, but immiscible at low temperatures, e.g.,
room temperature, phase separation can be induced upon cooling down
the polymer solution. In a preferred embodiment, the polymer is PCL
and the separation system is DMF/10% C3HgO3.
Cells to be Seeded onto the Mold or Polymer Scaffold
Within a single layer of the system, each channel will be divided
into two compartments, with the functional cells located in one
compartment, and the vasculature located in the other compartment.
The compartments of the channel are divided by the membrane.
Compartments of the channels within each layer typically include
one or more types of functional, mesenchymal or parenchymal cells,
such as smooth or skeletal muscle cells, myocytes (muscle stem
cells), fibroblasts, chondrocytes, adipocytes, fibromyoblasts,
ectodermal cells, including ductile and skin cells, hepatocytes,
kidney cells, pancreatic islet cells, cells present in the
intestine, and other parenchymal cells, osteoblasts and other cells
forming bone or cartilage, and hematopoietic cells. In some cases
it may also be desirable to include nerve cells.
"Parenchymal cells" include the functional elements of an organ
(e.g., organ-specific cells), as distinguished from the framework
or stroma. "Mesenchymal cells" include connective and supporting
tissues, smooth muscle, vascular endothelium and blood cells.
The membrane dividing the cells allows gas exchange, diffusion of
nutrients, and waste removal. Thus, one compartment comprises the
circulation through which blood, plasma or media with appropriate
levels of oxygen can be continuously circulated to nourish the
second compartment. The second compartment comprises a reservoir
for functional cells of one or more organs. The system optionally
includes inlets for neural inervation, urine flow, biliary
excretion or other activity.
Cells can be obtained by biopsy or harvest from a living donor,
cell culture, or autopsy, all techniques well known in the art.
Cells are preferably autologous. Cells to be implanted can be
dissociated using standard techniques such as digestion with a
collagenase, trypsin or other protease solution and are then seeded
into the mold or polymer scaffold immediately or after being
maintained in culture. Cells can be normal or genetically
engineered to provide additional or normal function.
Immunologically inert cells, such as embryonic or fetal cells, stem
cells, and cells genetically engineered to avoid the need for
immunosuppression can also be used. Methods and drugs for
immunosuppression are known to those skilled in the art of
transplantation.
Molecules such as growth factors or hormones can be covalently
attached to the surface of the molds and/or polymer scaffolds
and/or semi-permeable membrane to effect growth, division,
differentiation or maturation of cells cultured thereon.
Preferably, hepatocytes can be used with this invention. The
hepatocytes can be highly proliferative hepatocytes, known as small
hepatocytes (SHCs), which have the ability to proliferate in vitro
for long periods of time (Mitaka, et al., Biochem Biophys Res
Commun 214, 310 (1995); Taneto, et al., Am J Pathol 148, 383
(1996)). Small hepatocytes express hepatocyte specific functions
such as albumin production (Mitaka, et al., Hepatology 29, 111
(1999)).
Undifferentiated or partially differentiated precursor cells, such
as embryonic germ cells (Gearhart, et al., U.S. Pat. No.
6,245,566), embryonic stem cells (Thomson, U.S. Pat. Nos. 5,843,780
and 6,200,802), mesenchymal stem cells (Caplan, et al. U.S. Pat.
No. 5,486,359), neural stern cells (Anderson, et al., U.S. Pat. No.
5,849,553), hematopoietic stem cells (Tsukamoto, U.S. Pat. No.
5,061,620), multipotent adult stein cells (Furcht, et al., WO
01/11011) can be used in this invention. Cells can be kept in an
undifferentiated state by co-culture with a fibroblast feeder layer
(Thomson, U.S. Pat. Nos. 5,843,780 and 6,200,802), or by
feeder-free culture with fibroblast conditioned media (Xu, et al.
Nat. Biotechnol., 19, 971 (2001)). Undifferentiated or partially
differentiated precursor cells can be induced down a particular
developmental pathway by culture in medium containing growth
factors or other cell-type specific induction factors or agents
known in the art. Some examples of such factors are shown in Table
1.
TABLE-US-00001 TABLE 1 Selected Examples of Differentiation
Inducing Agents Agent Progenitor Differentiated Cell Vascular
Endothelial Embryonic Stem Cell Hematopoietic Cell.sup.1 Growth
Factor Sonic Hedgehog Floor Plate Motor Neuron.sup.2 Insulin-like
Growth Embryonic Stem Cell Myoblast.sup.3 Factor II Osteogenin
Osteoprogenitor Osteoblast.sup.4 Cytotoxic T Cell Spleen Cell
Cytotoxic T Lymyphocyte.sup.5 Differentiation Factor .beta.-catenin
Skin Stem Cell Follicular Keratinocyte.sup.6 Bone Morphogenic
Mesenchymal Adipocytes, Osteoblasts.sup.7 Protein 2 Stem Cell
Interleukin 2 Bone Marrow Precursor Natural Killer Cells.sup.8
Transforming Cardiac Fibroblast Cardiac Myocyte.sup.9 Growth Factor
.quadrature. Nerve Growth Factor Chromaffin Cell Sympathetic
Neuron.sup.10 Steel Factor Neural Crest Melanocyte.sup.11
Interleukin 1 Mesencephalic Dopaminergic Neuron.sup.12 Progenitor
Fibroblast Growth GHFT Lactotrope.sup.13 Factor 2 Retinoic Acid
Promyelocytic Granulocyte.sup.14 Leukemia Wnt3 Embryonic Stem Cell
Hematopoietic Cell.sup.15 .sup.1Keller, et al. (1999) Exp. Hematol.
27: 777-787. .sup.2Marti, et al. (1995) Nature. 375: 322-325.
.sup.3Prelle, et al. (2000) Biochem. Biophy. Res. Commun. 277:
631-638. .sup.4Amedee, et al. (1994) Differentiation. 58: 157-164.
.sup.5Hardt, et al. (1985) Eur. J. Immunol. 15: 472-478.
.sup.6Huelsken, et al. (2001) Cell. 105: 533-545. .sup.7Ji, et al.
(2000) J. Bone Miner. Metab. 18: 132-139. .sup.8Migliorati, et al.
(1987) J Immunol. 138: 3618-3625. .sup.9Eghbali, et al. (1991)
Proc. Natl. Acad. Sci. USA. 88: 795-799. .sup.10Niijima, et al.
(1995) J. Neurosci. 15: 1180-1194. .sup.11Guo, et al. (1997) Dev.
Biol. 184: 61-69. .sup.12Ling, et al. (1998) Exp. Neurol. 149:
411-423. .sup.13Lopez-Fernandez, et al. (2000) J. Biol. Chem. 275:
21653-60. .sup.14Wang, et al. (1989) Leuk. Res. 13: 1091-1097.
.sup.15Lako, et al. (2001) Mech. Dev. 103: 49-59.
A stem cell can be any known in the art, including, but not limited
to, embryonic stem cells, adult stein cells, neural stem cells,
muscle stem cells, hematopoietic stem cells, mesenchymal stem
cells, peripheral blood stem cells and cardiac stem cells.
Preferably, the stem cell is human. A "stern cell" is a
pluripotent, multipotent or totipotent cell that can undergo
self-renewing cell division to give rise to phenotypically and
genotypically identical daughter cells for an indefinite time and
can ultimately differentiate into at least one final cell type.
The quintessential stem cell is the embryonic stem cell (ES), as it
has unlimited self-renewal and multipotent and/or pluripotent
differentiation potential, thus possessing the capability of
developing into any organ, tissue type or cell type. These cells
can be derived from the inner cell mass of the blastocyst, or can
be derived from the primordial germ cells from a post-implantation
embryo (embryonal germ cells or EG cells). ES and EG cells have
been derived from mice, and more recently also from non-human
primates and humans. Evans et al. (1981) Nature 292: 154-156;
Matsui et al. (1991) Nature 353: 750-2; Thomson et al. (1995) Proc.
Natl. Acad. Sci. USA.
92: 7844-8; Thomson et al. (1998) Science 282: 1145-1147; and
Shamblott et al. (1998) Proc. Natl. Acad. Sci. USA 95:
13726-31.
The terms "stem cells," "embryonic stein cells," "adult stem
cells," "progenitor cells" and "progenitor cell populations" are to
be understood as meaning in accordance with the present invention
cells that can be derived from any source of adult tissue or organ
and can replicate as undifferentiated or lineage committed cells
and have the potential to differentiate into at least one,
preferably multiple, cell lineages.
Methods for Seeding Cells into Molds or Polymer Scaffolds
After the mold with the desired high degree of micromachining is
prepared, the molds themselves or polymer scaffolds are seeded with
the desired cells or sets of cells. The distribution of cells
throughout the mold or polymer scaffold can influence both (1) the
development of a vascularized network, and (2) the successful
integration of the vascular device with the host. The approach used
in this invention is to provide a mechanism for the ordered
distribution of cells onto the mold or polymer scaffold. Cells that
are enriched for extracellular matrix molecules or for peptides
that enhance cell adhesion can be used. Cells can be seeded onto
the mold or polymer scaffold in an ordered manner using methods
known in the art, for example, Teebken, et al., Eur J. Vasa
Endovasc. Surg. 19, 381 (2000); Ranucci, et al., Biomaterials 21,
783 (2000). Also, tissue-engineered devices can be improved by
seeding cells throughout the polymeric scaffolds and allowing the
cells to proliferate in vitro for a predetermined amount of time
before implantation, using the methods of Burg et al., J. Biomed.
Mater. Res 51, 642 (2000).
Seeding of each cell type is done by providing cells to each
compartment separately using microfluidic techniques. For example,
endothelial cells are introduced into the inlet of the vascular
network, and prevented from crossing over to a parenchymal
compartment by virtue of the small pores connecting the
compartments. Other compartments are filled by the same means,
keeping cell types in the desired locations.
In one embodiment, the mold or polymer scaffold is first seeded
with a layer of parenchymal cells, such as hepatocytes or renal
cells (e.g., proximal tubule cells). This layer can be maintained
in culture for a week or so in order to obtain a population
doubling. It can be maintained in a perfusion bioreactor to ensure
adequate oxygen supply to the cells in the interior. The system is
then seeded with a layer of endothelial cells and cultured further.
In regions where the matrix is resorbed rapidly, the tissue can
expand and become permeated with capillaries.
Cell Seeding of Horizontal Layer by Laminar Flow
Sets of cells can be added to or seeded onto a mold, which can
serve as a template for cell adhesion and growth by the added or
seeded cells. The added or seeded cells can be parenchymal cells,
such as hepatocytes or proximal tubule cells.
Stem cells can also be used. A second set of cells, such as
endothelial cells, can be added to or seeded onto the layers of the
system through other vessels than those used to seed the first set
of cells. The cell seeding is performed by slow flow. As a
practical matter, the geometry of the system will determine the
flow rates. In general, endothelial cells can enter and form vessel
walls in micromachined channels that are about 10-50 .mu.m. Thus,
in addition to serving as a mechanical framework for the organ, the
assembled system provides a template for all of the microstructural
complexity of the organ, so that cells have a mechanical map to
locate themselves and form subsystems, such as blood vessels in the
liver.
Channels in the horizontal direction typically proceed from larger
to smaller to larger. The geometries can be as complex as desired
in-plane (horizontal direction). Thus, one can use small geometries
in-plane (such as horizontal conduits of about 5-20 .mu.m). The
alignment of through-holes creates vertical conduits or channels in
the z-axis. However, the vertical channels need not go from larger
to smaller to larger. In the vertical direction, the vertical
channels are typically parallel to each other and have diameters on
the micron level, large enough only to allow cell seeding (e.g.,
hepatocytes are about 40 .mu.m). In one embodiment, different types
of cells are seeded horizontally onto different layers of the
assembled apparatus. In another embodiment, the different types of
cells are seeded using pores or channels from different directions.
Various combinations are also possible.
Extracorporeal Support Devices
The invention can be adapted to comprise devices for uses in
addition to the formation of implantable tissue. The devices can be
implantable. Alternatively, the systems can remain ex vivo, serving
as extracorporeal devices to supplement or replace biological
function. As used herein, the term "biological function" refers to
the structural, mechanical or metabolic activity of a tissue or
organ. Extracorporeal devices of the present invention can comprise
hybrid devices suitable for both ex vivo and in vivo use.
Extracorporeal devices, and may provide partial support function,
may extend the time between hospital treatments for patients on
chronic organ support therapies, and will improve the quality of
life between hospital treatments. For example, the device can be
adapted to produce an extracorporeal renal dialysis device, an
extracorporeal liver device, or an extracorporeal artificial lung
device. Such devices may or may not be supported with living cells
loaded or seeded into the device.
The systems of the invention can comprise a device to be implanted
into a subject to supplement or replace the biological function of
a tissue or organ.
In one embodiment, the system comprises an extra extracorporeal
renal dialysis device. Although the kidney is a complex organ with
an intricate vascular supply and at least 15 different cell types,
the critical functions of filtration, reabsorption and excretion
can be targeted with tissue engineering. The basic functional unit
of the kidney, the nephron, is composed of a vascular filter, the
glomerulus, and a resorptive unit, the tubule. Filtration is
dependent on flow and specialized glomerular endothelial cells. The
majority (50-65%) of reabsorption is performed by the proximal
tubule cells using active sodium transport through the
energy-dependent Na+-K+-ATPase located on the basolateral membrane.
Only 5-10% of the approximately one million nephrons in each human
kidney is required to sustain normal excretory function.
The design of a tissue engineered renal replacement device can then
be focused on the development of a glomerular endothelial filter in
conjunction with a proximal tubule device for reabsorption and
excretion. The endothelial filter is specifically designed to
provide physiologic flow with low thrombogenicity and maximized
surface area for solute transport. The proximal tubule device,
containing an appropriate number of cells for renal replacement,
has optimized surface area for solute reabsorption and an outlet
for urine excretion. Several layers of molds and/or polymer
scaffolds and semi-permeable membranes can be stacked to optimize
filtration and reabsorption. Biologically compatible, bioresorbable
and microporous polymers are used throughout for optimal cell
growth and function.
Systems of the invention can also comprise a device for use in
carrying out pharmacological studies of candidate drugs, to test
for toxicity and efficacy of lead compounds or existing drugs, to
replace suspect animal models and expensive clinical trials.
Methods for conducting drug screening using tissue engineered
devices are described in International Application No.
PCT/US04/01098, filed Jan. 16, 2004, the contents of which are
incorporated herein by reference for the description of methods to
be employed.
The following examples are put forth so as to provide those of
ordinary skill in the art with a complete disclosure and
description of how to make and use the invention, and are not
intended to limit the scope of what the inventors regard as their
invention.
EXAMPLES
Example 1
Fabrication of Silicon and Poly (Dimethylsiloxane) Molds
Photolithography is the first step in micromachining silicon to
define the nanoscale features that comprise the base layer. In this
first step, a photosensitive surface (photoresist) was etched
through the use of light. The photoresist was selectively exposed
using a designed template and then the exposed areas were
chemically removed in a developer. For this process, approximately
10 ml of Shipley's 1822 photoresist was used. The photoresist was
spun onto the silicon wafer at 5000 rpm, resulting in a resin
thickness of approximately 2 .mu.m. The areas to be etched away
were exposed in a Karl-Suss mask aligner. After exposure and
development, the portions of the silicon that were to be etched
into the vascular bed were visible and the parts that were not
etched were protected by the photoresist.
The prepared wafer was subsequently used to perform a deep reactive
ion etch using a Surface Technology Systems (STS) ion etch tool to
create the channels into the silicon. An average human capillary is
approximately 10-15 urn in diameter and endothelial cells are
approximately 10 urn wide. Thus, fully endothelialized blood vessel
of 10-15 microns in diameter necessitates a scaffold vessel
diameter of 30-35 m. To mimic this structure, channels of 30-35 pm
deep were etched.
The final step in the silicon fabrication process was the
deposition of a release layer to ensure that the PEG-VS
(polyethylene glycol-VS) gel did not adhere and tear during removal
from the wafer. For this capability, a C4F8 plasma coating (similar
to Teflon) layer of approximately 40 nm in thickness was deposited.
This was also performed in the STS etch tool.
Poly(dimethyl siloxane) (PDMS) was used as a secondary mold; the
monomer liquid was mixed with a polymerizing/cross-linking agent
(Sylgard 184) at a 10:1 ratio and about 80 grams was poured onto
the etched silicon wafer. The polymerization process required 2
hours at 65.degree. C. to solidify. Increased heating time resulted
in an increase in cross-link density, which yielded increased
stiffness and a higher likelihood of tearing. Cured PDMS molds were
excised with a square razor blade.
Example 2
Compression Molding of PLGA
The cross-linked PDMS mold was used to press melted poly (lactide
co-glycolide) (PLGA) into the desired layer structure. A PDMS mold
with a test pattern called J-Pore was placed on a rigid metal plate
and roughly 6 grams of Medisorb low IV PLGA 85:15 polymer pellets
were spread across the entire surface of the mold (FIGS. 15,16). A
top PDMS mold with an unpatterned surface was placed over the
pellet-covered bottom mold, while another rigid metal plate was
placed on top of the stack. The entire stack was then placed on a
hotplate at a temperature exceeding the glass transition
temperature (>55.degree. C.). During heating, approximately
100-300 lbs of force was applied to the stack for 8 minutes. After
8 minutes of simultaneous heat and pressure, the stack was removed
and the two rigid metal plates were removed. The PDMS stack was
placed on a flat metal surface and a large metal weight was placed
on top of the stack to press it during the cooling step. The stack
cooled under the metal weight for approximately 5 minutes, after
which the PDMS molds were peeled off from the PLGA layer and the
excess PLGA was cut away.
Example 3
Connecting and Bonding the Device
The PLGA layer was placed design-side down on a piece of PDMS. A
16-gauge syringe needle was heated with a heat gun and poked
through the inlets and outlets of the PLGA layer generating four
through-holes in each layer. The PLGA layer was then placed on a
piece of cardboard with holes punched out beneath the
through-holes. About 2 inches of size 020 silastic tubing was poked
through each through-hole such that about 1 centimeter protruded on
the design side. The tubes were secured in place by applying a
small amount of urethane around the circumference of the tube.
Urethane was allowed at least 30 minutes to dry. Any urethane and
tubing on the design side of the PLGA layer was trimmed off with a
sharp square razor blade.
When brought into molecular contact at a temperature above their
glass transition temperature, the macroscopic interface between the
surfaces of two pieces of similar polymer gradually disappeared and
the interface's mechanical strength increased. This phenomenon,
known as polymer welding or polymer healing, was used to bond PLGA
layers. A flat piece of PLGA was placed on a piece of PDMS. A PLGA
layer with the J-pore design and tubing in its inlets and outlets
was placed on top of the flat layer. Applying heat with a heat gun
for about 30-60 seconds bonded the layers.
Light microscopy of the pores between channels in a PLGA device
(FIG. 18A) showed that pores and channels were maintained in
bonding process. In FIG. 18B, pores can be seen in focus, while the
channels are out of focus. These images also demonstrated that the
pores became more difficult to detect after bonding, because they
were clearest when the rest of the design features were out of
focus.
Example 4
Testing the Microfabricated Device Using Fluorescent Beads
For flow testing, red fluorescent beads of 1-.mu.m in diameter were
diluted in distilled water at a 1:30 concentration. A Harvard
PHD2000 displacement syringe pump (Harvard Apparatus) was used with
a plastic syringe to infuse the solution of red fluorescent beads
into the vertical pore device at a flow rate of 10 L/min. Light
microscopy showed channels of 40 .mu.m in width and pores occluded
in the bonding process (FIG. 19). Red dye was flowed through the
lower channel and no red dye was detected in the upper channel.
This test showed that in the absence of pores, fluid could not
transfer from one channel into another. It also demonstrated that
the channels were not occluded in the bonding process and fluid can
flow through them. Where pores were maintained, the beads flowed
through into the other channel. Many beads gathered near the pores,
which made the pores fluoresce very brightly. Beads could be seen
passing through the pores and then flowing within the other
channel. This showed that the pores could allow fluid and small
particles to pass though from one channel into another.
Later tests used 6-.mu.m red fluorescent beads diluted to a 1:30
concentration. In channels that were 40-.mu.m wide, the 6-.mu.m red
fluorescent beads were flowed through the upper channel at a flow
rate of 10 .mu.L/min. The pores between the channels were
maintained. As shown in FIG. 21, the 6-.mu.m beads could not pass
through pores into other channel. They were observed lining up and
forming a row along the edge of the channel, but were unable to fit
through the pores. Water flowed through into the other channel, but
6-m beads were exclusively seen in the upper channel of the
device.
Having thus described in detail preferred embodiments of the
present invention, it is to be understood that the invention
defined by the appended claims is not to be limited to particular
details set forth in the above description, as many apparent
variations thereof are possible without departing from the spirit
or scope of the present invention. Modifications and variations of
the method and apparatuses described herein will be obvious to
those skilled in the art, and are intended to be encompassed by the
following claims.
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